Honeycomb filters with reduced number of unplugged partial peripheral cells and methods of manufacturing same

Abstract

A method of blocking partial cells at the periphery of diesel filters is disclosed. The method comprises plugging the partial cells with a suitable plugging material. In one embodiment, a line of plugging material is applied to either or both of the end faces of the diesel filter along an outermost row of partial cells to block same. In another embodiment, the outermost wall the diesel filter is first beveled to form a beveled edge and uniquely off-set the partial cells. Then the beveled edge has applied thereto a plugging material, such as a line or bead. A honeycomb structure having reduced number of unplugged partial cells at the periphery is also disclosed.

Description

TECHNICAL FIELD [0001] The present invention relates to honeycomb filter articles and methods of manufacturing the same. More particularly, the present invention relates to methods of plugging cells of honeycomb filters and honeycomb filters manufactured thereby. BACKGROUND OF THE INVENTION [0002] Diesel engines provide lower emissions and increased fuel economy compared to gasoline engines; however, if untreated diesel exhaust emissions are generally undesirable. Diesel particulate filters have been employed to control / treat particulate emissions from diesel-powered equipment such as trucks, buses, diesel electric locomotives and generators. Diesel particulate filters control diesel particulate emissions by physically trapping soot particles in their structure. [0003] A typical diesel particulate filter body may be fabricated using, for example, a honeycomb structure having a matrix of intersecting thin, porous walls that extend across and between its two opposing open end faces an...

AI Technical Summary

Benefits of technology

[0009] An additional advantage of the present invention is that the diesel filter is strengthened and is, therefore, more resistant to edge chipping. A more chip-resistant edge will reduce handing losses in the supply chain, as well as in the manufacturing plants.

[0010] According to further embodiment of the invention, a honeycomb filter is provided comprising a honeycomb body having a multiplicity of cells extending therethrough formed from intersecting walls and an outer wall bounding said cells wherein the cells located adjacent to the outer wall comprise partial cells, and a line of plugging material blocking the partial cells.

[0011] According to yet further embodiments of the invention, a honeycomb filter is provided comprising a honeycomb body having a multiplicity of cells formed of intersecting walls and an outer wall bounding the multiplicity of cells wherein the cells located adjacent to the outer wall comprise a row of partial cells, a bevel formed atop the row of partial cells, and plugging material applied to the bevel to block the partial cells. According to further embodiments of the invention, the plugging material is in the form of a line of plugging -material. The outer profile of the applied line of plugging material, which may be altered to form a desired profile.

Problems solved by technology

Diesel engines provide lower emissions and increased fuel economy compared to gasoline engines; however, if untreated diesel exhaust emissions are generally undesirable.

However, when such shapes are employed, a problem arises in that it is nearly always the case that an integral number of complete cells do not fit into the cross-sectional area of the diesel filter.

Generally, automated plugging equipment used to plug alternating cells in diesel filters have difficulty in finding and plugging these peripheral partial cells, so that unplugged partial cells at the periphery may exist.

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